Method of stone-surfacing fibrous materials



,C. CORYELL. METHOD OF STONE suancme maous MATERIALS.

" wrucmo'u m'zu 1m 9; 1919.

- PatentedSept. 28,1929.

UNITED STATES PATENT OFFICE.

WILLIAM CLAYTON CORYELL, OF YOUNGSTQWN, OHIO, ASSIGNOR TO THE GENERAE'. FIBEPROOFING COMPANY, OF YOUNGSTOWN. OHIO, A CORE'ORATION F OHIG.

METHOD STONE-SURFACING FIBROUS MATERIALS haseoes.

Application filed July 9, 1919. Serial No. 309,631.

To all out it may concern Be it known that I, lVILLmM CLAYTON (:OltYELL, citizen of the United States, residing at Youngstown, in the county of Mahomng and State of Ohio. have invented certain new and useful improvements in Methods of Stone-Surfacing Fibrous Materials of which the following is a specification.

This invention relates to the general subject of coating processes and more particularly to the surface coating of fibrous materials having an oiled or waterproof surface.

(lertain materials are rendered more available for industrial purposes .by being subjected to treatment to render the same waterproof and fire-resistant, and that particularly applies to building materials or building fabrics which are employed as substitutes for wood and metal lathing and for other building purposes. It is quite important in the production ofa building fabric for such purposes that the fibrous sheet forming the body part of the fabric shall be treated with a suitable water repelling substance as oil, tar or equivalent medium, and it is likewise desirable and import-ant to supplement this treatment by providing the waterproofed body with a coating or envelop of a non-combustible artificial stone compound so as to render the completed product quite fire-resistant. This will also apply to any fibrous material or fibrous ob-. ject in which it is desired to supplement the waterproofing treatment by a fireproofing treatment, and the present invention has chiefly in View a novel method of combining waterproofing and fireproofing treatment of a fibrous materialin such a'manner as to obtain an ell'ective and homogcnous bonding between the oiled or waterprtmt surface. and the stone-surfacing of non-comluistible'material as for instance an artificial stone. conn pound.

e The. invention is necessarily susceptible of modification within the limits of the-appended claims but may be well exemplified by the graphic illustrations of the drawings.

wherein Figure l is a greatly magnified view of a section of fibrous material such as paper.-

rope. felt or other equivalent. the fibers of which have been given a bath of oil. asphal= turn or other waterproofing substance.

Fig. 2 is a view of the same section of fibrous material showing the important intermedia-ry step of the process wherein the interstiees'or spaces between the fibers have I been filled in with non-oily particles of a noncombustible material.

Fig. 3 is a view of the same material show ing the, general step of the-process wherein the artificial stone compound has been amalgamated or consolidated witlra non-oily fill ing material.

In carrying out the method of the present invention it will be understood, as above indicated, that the same isnot limited in its application to any particular fibrous materials which are to be water-proofcil and [he proofed, nor is it confined to the use of any particular substances or compounds for primarily water-proofing the fibers, then filling in the pores or interstices with a non-oily substance. and finally producing a homogenous artificial stone coating or surface. Accordingly, it will be understood that the distinctive and important feature of the invention resides in the method which is employcd. by the use of suitable substances. for thepurpose of obtaining an effective bond between the waterproofed surface and the stone-surfacing of non-combustible material. This may be well explained by reference to the graphic illustrations of the drawings. In these illustrations the fibrous material designated as F is shown highly magnified or enlarged to expose the pores orwith an oily waterproofing substance the latf tcr provides an unctuous or greasy surface on and throughout the fibrous body wan-l: acts to prevent the adhesion of water or 'watery substances and therefore is repellent This makes it difiicult and almost thereto. impossible for the fibrous material thus watcrprooted to receive or contain any continuous coat and arti-ficialstone compound which is usually in liquid form with a considerable percentage of water therein.

' 'lh'erelore it is proposed by the present in vcntion to introduce in the process of stone surfacing a waterproofed or oiled material an intermediary step which provides for pro paring the material n such a way that artificialistone com )ouud ma be thorou hl Y and effectively bonded into and on the material. The treatment of the waterproofed or oiled fibrous material which renders this desirable result possible consists in filling, as completely as possible, the pores or interstices betweenthe fibers with a non-oily sub stance such as very fine sand or dust. This non-oily substance may be incorporated in the-waterproofed or oiled fibrous material in any suitable manner as by rubbing, pressa ing or otherwise working the sameinto' and throughout the fabric so that the pores or interstices thereof will be filled thereby'as shown by the graphic enlargement of Fig. 2

of the drawings, the said non-oily filling material being indicated in said figure by the.

reference numeral 1. v

The non-oily filler when thus intimately incorporated with and throughout the fibrous,

material becomes tightly interlocked therewith and presents a body to which an artifi-- cial stone compound. can be effectually bonded. In fact a filler material of the character referred to readily induces stone-forming compounds when liquid to wet the. surface, and such compound while solidifying will in effect .incorporate, by adhesion or otherwise, the non-oily particles of non-combustible material into its'own body, thereby ad hering to or becoming interlocked with the stone-like body 2 throughout the fibrous ma-' terial and forming the surface therewith.

3' Should it be desirable, in. carry-ing forward the process'to facilitate and expedite the drying of the stone compound the latter when in the liquid state may be sprinkled with a non-combustible dust or granular substance, as sand. This dusting operation, furthermore, has the effect of thickening the stone coating and giving the finishedsurface a granular or san'cl stone. finish or texture and also tending to close any crack or fissures that might develop in the drying of the stone compound.

From he foregoing itis thought that the particular features of the invention have been-fully pointed out, though it will be .un-

derstood that any minor variations therein may be resorted to without departing from the spirit or sacrificing any of the advan-. pages of the invention.

claim l. The herein described method of preparing fibrous sheet materials which consists in preliminarily filling the pores or interstices opening at the exposed faces thereof With a'powdered fillin substance, and sub- 'sequently'. enveloping t e said material and filling substance w1th a plastic artificial stone compound,

21 The herein described method of preparing fibrous material impregnated with an oily substance which consists in'preliminarily fillirig the pores or interstices thereof with an non-oily dry dust, and subsequently saturating thesai'd material and dry dust fillerwith a plastic artificial stone compound. 1 y

The herein described method of reparing relatively porous water repel ing sheet-which consists in preliminarily subjecting the said relatively orous sheet to a bath of non-combustible ust', and subsequ'ently applying inliquid form a layer of non-combustible substance.- I

4.'The herein described method of reparing. relatively porous water repel ing sheet which consists in preliminarily subjecting the said relatively porous sheet to a bath of non-combustible dust', then apply.- ing in liquid forma layer 'of non-combusv tible substance, and subsequently drying the latter. by an application of a coat of non combustible dust.

5. A method of wet. r-proofing and fireproofing 1 relatively porous sheet materials havin an .oily .base which consists in first applying to said base a waterproofin substance inform of a dust to fill the voids of the relatively porous base, and subsequently applying an artificial stone compound in liquid form to the dust impregnated base.

6. A method, of water-proofing and fire- ,proofing relatively porous sheet materials having an oily combustible base,-which consists in first rubbing a dust of water-proofing substance into the voids of the relatively porous base, and subsequently applyin a coating of liquid artificial stone compound to the dust impregnated base to envelop the same.

signature in the presence of two witnesses.

WILLIAM CLAYTON CORYELL. Witnesses: I f

.Ror F.-LAND,

H. E, WHITE,

In testimony whereof I hereunto alfix my 

